Roberts Gorden UltraVac Installation Manual Download Page 36 | Manualshive

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ROBERTS GORDON

®

ULTRAVAC™ C

ONTROLLER

I

NSTALLATION

M

ANUAL

30

FIGURE 20: End Vent Vacuum

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5

4
3
2
1

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1
2
3
4

5
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Manometer

Insert

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about

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end

vent

.

Combustion

Chamber

at

end

burner

position

End

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Appro

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readin

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ter

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ustin

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VFD

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requency

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2

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Summary of Contents for UltraVac

Page 1: ... time to read and understand these instructions prior to any installation Installer must give a copy of this manual to the owner Owner Keep this manual in a safe place in order to provide your serviceman with necessary information Roberts Gordon LLC 1250 William Street P O Box 44 Buffalo New York 14240 0044 Telephone 716 852 4400 Fax 716 852 0854 Toll Free 800 828 7450 www rg inc com 2008 Roberts ...

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Page 3: ...irements 12 3 4 Electrical Installation Requirements 13 3 5 Pump Requirements 13 3 6 Variable Frequency Drive Requirements 13 3 7 Indoor Sensor Placement 14 3 8 Outdoor Sensor Placement 14 3 9 Outside Air Supply 14 SECTION 4 Typical External Diagrams 15 SECTION 5 Communications 20 5 1 Dedicated Phone Line for Central Controller Modem 20 5 2 RS 485 Converter for Central Controller 21 5 3 TCP IP Com...

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Page 5: ...r Communication Equalization Wiring 15 Figure 11 ROBERTS GORDON ULTRAVAC Central Controller External Wiring 16 Figure 12 ROBERTS GORDON ULTRAVAC Satellite Controller External Wiring 18 Figure 13 Modem Location 20 Figure 14 RS 485 PC Connection 21 Figure 15 TCP IP Communication Module Mounting 22 Figure 16 TCP IP Communication Module Wiring 23 Figure 17 9 Pin Adapter for PC 24 Figure 18 Communicati...

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Page 7: ...anty See Page 41 Section 10 ROBERTS GORDON ULTRAVAC Software requires a PC not supplied running Windows 95 or higher with a Pentium class processor and at least 64k of RAM The controller variable frequency drive burners pump and outside air blower must be electrically grounded in accordance with the National Electrical Code ANSI NFPA 70 latest revision Before proceeding with the installation of th...

Page 8: ...N RS485 OUT RS485 OUT RS485 OUT RS485 OUT 1 4A 1 4A 1 4A 1 4A ULTRAVAC Software P N 10080421 ULTRAVAC Software Manual P N 10081600NA ULTRAVAC Installation Manual P N 10081601NA TCP IP LAN Communication Module w 7 phone wire P N 10080440 Comms Equalization Cable P N 10080450 Outdoor Sensor P N 10081501 PC Connection Cable Package P N 10080410 Line Voltage 120 V Wiring Low Voltage 24 V Wiring POWER ...

Page 9: ...L2 GRD OUTPUT 3 L1 L2 GRD OUTPUT 4 L1 L2 GRD OUTPUT 5 L1 L2 GRD OUTPUT 6 L1 L2 GRD OUTPUT 7 L1 L2 GRD OUTPUT 8 L1 L2 GRD 1 2 4 3 5 6 7 8 REF 24VAC L2 NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C RS485 COMM REF 1 2 3 4 METER INPUTS UNIVERSAL INPUTS IN OUT ADDRESS RESET 10VDC 499 OHM OFF ON OUT IN G IN OUT G G G 5 32 AUX POWER RS232 DIRECT RI CD OH CPU L1 PWR 1 2 3 4 METER INPUTS ...

Page 10: ...L2 GRD OUTPUT 1 L1 L2 GRD OUTPUT 2 L1 L2 GRD OUTPUT 3 L1 L2 GRD OUTPUT 4 L1 L2 GRD OUTPUT 5 L1 L2 GRD OUTPUT 6 L1 L2 GRD OUTPUT 7 L1 L2 GRD OUTPUT 8 L1 L2 GRD 1 2 4 3 5 6 7 8 REF 24VAC L2 NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C RS485 COMM REF 1 2 3 4 METER INPUTS UNIVERSAL INPUTS IN OUT ADDRESS RESET 10VDC 499 OHM OFF ON OUT IN G IN OUT G G G 5 32 AUX POWER RS232 DIRECT RI ...

Page 11: ...llation operation or service of this equipment For optimum heater performance and safe heating conditions inspect and maintain heater s before every heating season and as necessary Also know and maintain heater clearances to combustibles see heater Installation Operation and Service Manual for further details If you require additional manuals con tact your ROBERTS GORDON independent distrib utor o...

Page 12: ...N MANUAL 6 FIGURE 1 Example Site Layout NOTE Conceptual drawing not to scale Venting not shown Zone 1 Zone 2 Zone 3 Zone 2 Sensor Zone 1 Sensor Zone 3 Sensor Variable Frequency Drive North Wall Outside Sensor Pump ROBERTS GORDON ULTRAVAC Controller ...

Page 13: ...utputs Single Pole 3 A 120 Vac UL Standard UL 916 C22 2 No 205 M1983 2 2 Temperature Sensors Indoor Sensor Dimensions 2 75 w x 4 5 h x 1 15 d Power 32 V DC Features LCD temperature display setpoint adjustment override button Wiring Shielded Cable four twisted pairs 24 AWG min Outdoor Sensor P N 10081501 Dimensions 1 4 w x 5 3 h x 2 d Enclosure NEMA 4 gasketed aluminum LB housing threaded connectio...

Page 14: ...UT 8 L1 L2 GRD 120 Vac Outputs Plug In Relays 24 V Power Switch Control Board Transformer Meter Inputs Analog Output Board Modem Phone Port Analog Inputs Eprom Chip Selector Switch Reset Button RS 485 Terminals RS 232 Direct Connect Port 24 V Board Power Input 24 V Control Board Power Supply Relay Board 24 V Power 1 A Fuse Sensor Power 120 Vac Power Input Modem Chip optional only located on Contro...

Page 15: ...R 4 12 13 2 3 2 Electrical Power Output 230 V 3 Ø 0 60 Hz for 115 V and 230 V models 460 V 3 Ø 0 60 Hz for 460 V models Speed Reference Follower 0 10 Vdc UL Standard Industrial Controls Equipment Ambient Operating Temp 32 F 104 F 0 C 40 C 75 HP 230 V Drive used with EP 203 pump P N VFD75230 or VFD75230N4 Power Input 208 240 V 1 Ø 50 60 Hz Input Voltage Tolerance 10 Amps 6 9 6 0 A 1 HP 120 V Drive ...

Page 16: ...13B 13E 25 16 17 PE PE W V U L2 N L1 B PE B Variable Frequency Drive 1 Ø input model shown Terminal Inputs 230 V 3 Ø or 460 V 3 Ø outputs Grounding Block 120 V signal from relay board output 8 Relay 120 V Rotary Disconnect Input Fuse Holder 1 Ø input model shown 3 Ø input models have an additional input fuse holder and VFD power input VFD Enclosure Standard Enclosure Shown ...

Page 17: ...azard ous vapors or dust excessive moisture or dirt vibration To avoid damage from possible drips do not mount controller or VFD directly beneath pump Models with NEMA 4 rated enclosures will withstand exposure to dust dirt and water VFD should be mounted in locations where the maximum ambient temperature does not exceed 104 F 40 C Avoid installing the VFD in mezza nines direct sunlight or near ex...

Page 18: ...d 24 AWG min wire is required for use with indoor sensors See Page 12 Figure 5 for an illustration of the shielded cable specification to be used See Page 12 Section 3 3 2 to see if unshielded cable may be used Unshielded Cable AMP 57248 219538 219513 Belden 1585A 1583A General Cable C6015 or equivalent Shielded Cable Madison Cable 08CF J10001 08CFJ00004 Belden 9681 General Cable 2131673 C1676 or ...

Page 19: ...e power supply must be 230 V 50 60 Hz 1 Ø The 120V drive power supply must be 120 V 50 60 Hz 1 Ø The 460 drive power supply must be 460 V 50 60 Hz 3 Ø See Page 9 Section 2 3 for additional details The VFD on off switching is done by an output on the relay board The 0 10 V signal from the ULTRAVAC controller enclosure wired into VFD input relays 5 and 2 see Page 16 Figure 11 through Page 18 Figure ...

Page 20: ...g the plug in LCD display from its socket secure the sensor to the wall or junction box using the screws provided Replace the plug in LCD dis play and secure the cover with the two 1 16 allen screws Wiring from 32 V terminals on the controller to sensor power terminals and is polarity sensitive Reversing polarity may cause sensor damage Refer to Page 16 Figure 11 and Page 18 Figure 12 for wiring d...

Page 21: ...d RED BLACK RED BLACK 120 ohm resistor included w P N 100800450 Shrinkwrap All ULTRAVAC Central Controllers are shipped with a communication equalization cable P N 10080450 The cable is supplied to equalize and balance the circuitry of the communications on the controller network that may be experiencing noise or transient voltage levels Connect the communi cation equalization cable as shown below...

Page 22: ... supply for 230 V VFD model 460 V 3 Ø 50 60 Hz supply for 460 V VFD model See VFD rating plate for required input Repetitive cycling of a disconnect or input contactor more than once every two minutes may cause damage to the drive NOTE 4 Zone 3 Sensor not shown wiring is as follows SEN output to analog input 3 SET output to analog input 6 O R output to meter input 3 outputs to 32 V GND inputs NOTE...

Page 23: ...D Assembly 1 Ø input VFD model shown L1 L2 L1 L2 L1 L2 L1 L2 L1 L2 230 V 3 Ø 0 60 Hz To Terminal 5 To Terminal 2 L1 L2 Zone 3 Burners L1 L2 L1 L2 Outside Air Blower optional Zone 2 Burners Zone 1 Burners T2 T3 Continued From Previous Page To Terminals 13 and 14 Motor Power Supply see NOTE 7 460 V 3 Ø 0 60 Hz for 460 V input VFD models or M16 12 P M16 12 P 1 2 5 6 11 13A 13B 13E 25 16 17 PE PE W V ...

Page 24: ... or outdoor sensor wiring For Central Controller see Central Controller External Wiring Diagram NOTE 2 Twist shield wires for both RS 485 communication cables together and ground at central panel only On controller 1 only connect these twisted shield wires to ground For VFD 0 10 V signal wiring connect shield wire to ground at the controller only NOTE 3 120 V 1 Ø 50 60 Hz supply for 120 V VFD mode...

Page 25: ...erminals 13 and 14 T2 T3 Continued From Previous Page Motor Power Supply See NOTE 7 Pump 230 V 3 Ø 0 60 Hz for 115 V and 230 V input VFD models 460 V 3 Ø 0 60 Hz for 460 V input VFD models or Outside Air Blower optional VFD Power Supply 1 Ø input VFD model shown see NOTE 3 VFD Assembly 1 Ø input VFD model shown To Terminal 5 To Terminal 2 M16 12 P M16 12 P 1 2 5 6 11 13A 13B 13E 25 16 17 PE PE W V...

Page 26: ...ULTRAVAC controllers are being used the additional controllers communicate to controller 1 through communication wiring arranged in series from one controller to the next See Page 25 Section 5 5 FIGURE 13 Modem Location 5 1 Dedicated Phone Line for Central Controller Modem The Central Controller is fitted with a modem chip To use the modem the controller must have a phone line for modem communicat...

Page 27: ...communication wiring arranged in series from one controller to the next See Page 25 Section 5 5 This allows multiple controllers to be controlled from a PC through a single communication package at the central controller FIGURE 14 RS 485 PC Connection 1 2 4 3 5 6 7 8 REF RS485 COMM REF 1 2 3 4 METER INPUTS UNIVERSAL INPUTS IN OUT ADDRESS RESET 10VDC 499 OHM OFF ON OUT IN G IN OUT G G G 5 32 AUX PO...

Page 28: ...an be found in the ROBERTS GORDON Software Manual For TCP IP communication module wiring details see Page 23 Figure 16 If multiple ULTRAVAC controllers are being used the additional controllers communicate to controller 1 through RS 485 communication wiring arranged in series from one controller to the next See Page 25 Section 5 5 This allows multiple controllers to be controlled from a PC through...

Page 29: ...LACK 120 ohm resistor included w P N 10080440 Shrinkwrap RS 232 Direct Port Dip Switch 1 set to ON Red Black RS 45 Jack Ethernet Cable to LAN RJ 11 Jack Standard 4 Wire Phone Cord included Communications Circuit Equalizer Wiring included module power wire Description Part Number TCP IP Communication Module 10080440 It is important that the module power wire is connected as shown black 5 V red 5 V ...

Page 30: ... into the RS 232 direct port plug the other end into the adapter shown in on Page 24 Figure 17 Plug the adapter into a 9 pin serial port on your computer If a PC does not have a serial port but does have a USB port purchase of a USB to Serial Converter is required A USB to 9 pin Serial Cable will allow connection between the RS 232 device ULTRAVAC Control Board and the USB port on the PC The USB t...

Page 31: ...WR 1 2 4 3 5 6 7 8 REF 24VAC L2 NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C RS485 COMM REF 1 2 3 4 METER INPUTS UNIVERSAL INPUTS IN OUT ADDRESS RESET 10VDC 499 OHM OFF ON OUT IN G IN OUT G G G 5 32 AUX POWER RS232 DIRECT RI CD OH CPU L1 PWR 1 2 4 3 5 6 7 8 REF 24VAC L2 NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C RS485 COMM REF 1 2 3 4 METER INPUTS UNIVERSAL ...

Page 32: ...GURE 19 Repeater Wiring RS232 RS485 RS485 OUT REF PROGRAM RUN RS485 OUT RS485 OUT RS485 OUT RS485 OUT 1 4A 1 4A 1 4A 1 4A Red Black Red Black Red Black Drain Red Black RS232 RS485 RS485 OUT REF PROGRAM RUN RS485 OUT RS485 OUT RS485 OUT RS485 OUT 1 4A 1 4A 1 4A 1 4A Red Black Red Black Red Black RS232 RS485 RS485 OUT REF PROGRAM RUN RS485 OUT RS485 OUT RS485 OUT RS485 OUT 1 4A 1 4A 1 4A 1 4A Red Bl...

Page 33: ...word Once the correct password value is entered the dis play will read P01 which indicates that the PROGRAM mode has been accessed at the begin ning of the parameter menu P01 is the first parameter NOTE If the display flashes Er the password was incorrect and the process to enter the password must be repeated 6 1 3 Use the arrow buttons to scroll to the desired parameter number For new parameter s...

Page 34: ...r to access the parameters again 6 2 Altering VFD Parameters Using the procedure described in Section 6 1 1 through Section 6 1 5 alter the following parameters Parameter Number Parameter Name Factory Default New Setting P16 Units Ending 02 01 P44 Password 225 Any 000 999 P03 Start Method 01 05 ...

Page 35: ...uld light within 60 seconds At the VFD verify that the number displayed on the LCD screen is 60 0 If it is lower than 60 0 hit the up arrow button on the VFD until the number reads 60 0 Let the burn ers fire for approximately 20 30 minutes to warm up the system Using a manometer check the end vent vacuum in each zone each branch of burners See Page 30 Figure 20 If the lowest end vent vacuum readin...

Page 36: ...NUAL 30 FIGURE 20 End Vent Vacuum 6 5 4 3 2 1 0 1 2 3 4 5 6 Manometer Insert tubing about 6 15cm into end vent Combustion Chamber at end burner position End Vent Approximate reading after adjusting VFD frequency setting and or damper couplings 2 5 3 wc ...

Page 37: ...FIGURE 21 Possible Damper Couplings Locations Damper Coupling Damper NOTE Damper setting will vary Zone 1 Zone 2 Zone 3 Zone 1 End Vent Zone 3 End Vent Zone 2 End Vent Zone 1 Damper Coupling Zone 2 Damper Coupling Zone 3 Damper Coupling Pump Damper ...

Page 38: ...on the VFD s LCD screen 1 0 w c 1 2 wc VFD Frequency Setting Step 7 1 4 Return to the PC and click the pump and zones to OFF Step 7 1 5 Using the procedure described in on Page 27 Section 6 1 1 through Section 6 1 5 alter the fol lowing parameters on the VFD Step 7 1 6 Return to the PC and click the vacuum pump and three zones to AUTO then click exit Parameter Number Parameter Name Factory Default...

Page 39: ...VAC Outdoor Sensor not shown 10081501 ROBERTS GORDON ULTRAVAC Indoor Sensor C not shown 10081502 PC Connection Cable Package not shown 10080410 RS 485 Converter Package not shown 10080430 TCP IP Communication Module not shown 10080440 1 2 4 3 5 6 7 8 REF 24VAC L2 NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C NO NC C RS485 COMM REF 1 2 3 4 METER INPUTS UNIVERSAL INPUTS IN OUT ADDRESS RESE...

Page 40: ...th EP 203 10081201 Variable Frequency Drive 3 4 HP 230 V 1 Ø Input for use with EP 203 10081202 Variable Frequency Drive 2 HP 230 V 1 Ø Input for use with EP 303 10081203 Variable Frequency Drive 1 HP 460 V 3 Ø Input for use with EP 203 10081204 Variable Frequency Drive 2 HP 460 V 3 Ø Input for use with EP 303 10081205 Relay 120 V 90429100 Fuse 10 A for 75 HP 230 V VFD 1 HP 460 V VFD and 2 HP 460 ...

Page 41: ...te the 1A fuse and remove it from its socket using a flathead screwdriver Twist the fuse a 1 4 turn counter clockwise until the fuse pops out of the socket Replace it with a new fuse Slide the fuse back into the socket press down and turn the fuse a 1 4 turn clockwise until secure Return 120 V power to the relay board and turn on the 24 V power switch on the relay board Press the reset button on t...

Page 42: ...rd Inside the VFD assembly open the fuse holder by pulling down the lever to expose the fuse Remove the old fuse and insert a new fuse Verify the correct fuse rating 25 A for 1 HP 120 V VFD or 2 HP 230 V VFD 10 A for the 75 HP 230 V VFD 1 HP 460 V VFD and 2 HP 460 V VFD Close the fuse holder Return power to the VFD assembly and verify that the VFD LCD screen is on dashes displayed Close the VFD as...

Page 43: ...OBERTS GORDON Independent Distributor Are shield wires from RS 485 communication bus wiring and VFD 0 10 V signal wiring correctly twisted and or grounded Yes START On the Manual Override screen Alt M set the pump status to Auto Does the pump go on No Yes No Press the reset button on the control board Is the red RUN light blinking Is the bulb for the pump light on the controller burnt out No Yes N...

Page 44: ...ere power 120 V or 230 V between the rotary disconnect inputs No No No Yes Yes Yes Is there power 120 V or 230 V between fuse holder inputs No Yes Is there power 120 V or 230 V between fuse holder outputs No Yes Is there power 120 V or 230 V between L1 and L2 N inputs on the VFD No Yes Is the LCD display of the VFD on Rectify wiring between 120 V relay and VFD terminals 1 and 11 No Yes Is there co...

Page 45: ... Is there 24 Vac across the control board 24 V output 1 3 for that zone No Yes Is there continuity across meter input 4 pressure switch input on the control board Do all the burners ignite smoothly No No On the relay board is the appropriate zone relay 1 3 LED lit After 45 seconds pre purge period do the burners light No Verify pressure switch wiring and operation Replace pressure switch if necess...

Page 46: ...necessary No Yes Are the filters on the burners dirty Is the rotation of the pump motor correct Yes No Adjust system for proper vacuum at the end vent See Commissioning of the CRV System for details Is the vacuum setting too low No Yes Is the flame low No Yes No Yes Are the filters on the burners dirty Yes No Is the rotation of the pump motor correct Follow burner check procedure given above No Ye...

Page 47: ...annual maintenance history The data plate and or serial number are removed defaced modified or altered in any way The ownership of the ROBERTS GORDON ULTRAVAC is moved or transferred This warranty is nontransferable Roberts Gordon is not permitted to inspect the damaged controller and or component parts READ YOUR INSTALLATION OPERATION AND SERVICE MANUAL If you have questions about your controller...

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